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UK Weblab – Setup and Use

UK Weblab – Setup and Use. Markus Kraft, Andreas Braumann, Charles Immanuel, Phillip Robbins 14 March 2008. People. Markus Kraft, Andreas Braumann Charles Immanuel Phillip Robbins. The Weblab project. Cambridge-MIT Institute (CMI) Prof Clark Colton (MIT), Dr Markus Kraft (CU)

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UK Weblab – Setup and Use

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  1. UK Weblab – Setup and Use Markus Kraft, Andreas Braumann, Charles Immanuel, Phillip Robbins 14 March 2008

  2. People • Markus Kraft, Andreas Braumann • Charles Immanuel • Phillip Robbins

  3. The Weblab project • Cambridge-MIT Institute (CMI) • Prof Clark Colton (MIT), Dr Markus Kraft (CU) • Explore the use of remotely accessible experiments in chemical engineering curriculum • MIT heat exchanger • Cambridge reactor

  4. Cambridge Weblab • Chemical Reactor • Industrial Process Control System (PCS7) • Set up in 2006 • used at differentuniversities

  5. Selmer and Goodson Anders Selmer Mike Goodson

  6. Equipment • Chemical Reactor • Ancillary equipment • SIMATIC S7-400 controller • Siemens Industrial PCs

  7. Reactor • 100 – 300 ml variable volume • Variable, ideal – non ideal • Variable stirrer speed • Temperature controlled • Three controlled feeds • Conversion monitored by spectrometer • Dosing of tracer

  8. Ancillary Equipment • Storage tanks • Siemens Coriolis flow meters • Peristaltic pumps

  9. Ancillary Equipment • Dosing unit • Heater bath • Flow cell with fibre optics • Spectrophotometer • Webcam

  10. Computers • Programmable Logical Controller (PLC) SIMATIC S7-400 • Engineering Station • Operating System Server • Web Server

  11. Plant wiring scheme Analogue and Digital Inputs/Outputs Dosing S7 400 Heater bath AI AO DI DO Hot water circulation ET 200M Stirrer, 0-5V PROFIBUS DP Plant Bus (Industrial Ethernet) OS Server Engineering Station SPM 4-20 mA Peristaltic pumps, 0-4V Terminal Bus (Industrial Ethernet) MASSFLO MASS DI 1.5 SITRANS T DP Link Web Server(PCS7 Client) Internet DP/PA Coupler PROFIBUS PA PCS7 OS Web Client

  12. Graphical User Interface • Mimic • Block Icons • Faceplates • Trends

  13. Non-ideal Reactor Exercise Ideal and non-ideal reactor • Reaction constants based on batch data • RTD tests • Predict required flow rates for desired conversion under continuous operation • Experimental session to test predictions

  14. Users • University of Cambridge • MIT • Imperial College London • University of Birmingham • University of Newcastle • Loughborough University

  15. Imperial College London • Enormous educational value in hands-on laboratory experiments - Course: Process Modelling, Dynamics and Control • Industry standard control software - Siemens distributed control system • Ideal process - Challenging yet realistic

  16. Process Dynamics & Control Exercise • Dynamic modelling • - experimental data for validation • Design of feedback controllers • - tuned through experiments, • empirical tuning laws, and • theoretical considerations • Design of feedforward • controllers • Experimental testing of the • controller effectiveness • - faced with real-life vagaries

  17. Process Dynamics & Control Exercise Manipulated variable • Dynamic modelling • - experimental data for validation • Design of feedback controllers • - tuned through experiments, • empirical tuning laws, and • theoretical considerations • Design of feedforward • controllers • Experimental testing of the • controller effectiveness • - faced with real-life vagaries Controlled variable

  18. Process Dynamics & Control Exercise • Student comments • - very enjoyable/ challenging • - opportunity to appreciate • limitations of theory • Lecturer comments • - excellent motivational tool • - cover much ground through single • exercise

  19. Weblab – University of Birmingham Who used it? 2nd Year chemical engineering undergraduates Which course? Forms part of a linked control course, the first half is Process Systems, and the second Principles of Process Control within the Chemical Engineering at Birmingham. Why? Wanted to have an experiment as part of the control laboratories that showed something of what a modern PLC control interface would look like and something of what is technically possible in terms of remote operation.

  20. Weblab – University of Birmingham How? A lab experiment sheet was written to take the students through the use of the Weblab and then to look at estimating some suitable control parameters from performing step changes. It forms one of a series of labs the students look at. The other labs cover aspects of control more related to the taught material than the ‘real’ world.

  21. Weblab – University of Birmingham Overall experience? Staff/demonstrators: Has worked well, it is ‘low’ maintenance and the additional details available on the website allow the students to get a good feel for what the control equipment actually looks like and what it is for. Students: A very positive response, most like the idea of being able to control a rig in Cambridge, having the webcam means they can also see changes occurring.

  22. Weblab – University of Birmingham Thanks to staff at Cambridge who have supported the Weblab use Markus Kraft Andreas Braumann Mike Goodson Jon Etheridge And at Birmingham to Dr Chris Kent and various demonstrators.

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